500 WATT MXW SERIES DC/DC CONVERTER Product Overview The 4:1 Input Voltage 500 Watt Single MXW DC/DC converter provides a precisely regulated dc output. The output voltage is fully isolated from the input, allowing the output to be positive or negative polarity and with various ground connections. The 500 Watt MXW meets the most rigorous performance standards in an industry standard footprint for mobile (12VIN), process control (24VIN), and military COTS (28VIN) applications. The 4:1 Input Voltage 500 Watt MXW includes trim and remote ON/OFF. Threaded through holes are provided to allow easy mounting or addition of a heatsink for extended temperature operation. (Non-threaded option is available, see ordering information under model selection table.) * * * * * * * * * * * * * * * * * 4:1 Input voltage range High power density Small size 2.4" x 2.5" x 0.52" Efficiency up to 95.7% Excellent thermal performance Metal Baseplate Over-Current and Short Circuit Protection Over-Temperature protection Auto-restart Monotonic startup into pre-bias Constant frequency Remote ON/OFF Good shock and vibration damping Temperature Range -40C to +105C Available RoHS Compliant UL60950 Approved 5 Year Warranty The converters high efficiency and high power density are accomplished through use of high-efficiency synchronous rectification technology, advanced electronic circuit, packaging and thermal design thus resulting in a high reliability product. Converter operates at a fixed frequency and follows conservative component de-rating guidelines. Model Input Range VDC Vout VDC Iout ADC Min Max 24S12.41MXW (ROHS) 9 36 12 41 24S24.21MXW (ROHS) 9 36 24 21 24S28.18MXW (ROHS) 9 36 28 18 1. Negative Logic On/Off feature is available. Add "-N" to the part number when ordering. i.e. 24S12.41MXW-N (ROHS) 2. Available with non-threaded mounting inserts. Add -I to the part number when ordering. i.e 24S28.18MXW-I (ROHS) 3. Designed to meet MIL-STD-810G for functional shock and vibration. The unit must be properly secured to the interface medium (PCB/Chassis) by use of the threaded inserts of the unit. 4. A thermal management device, such as a heatsink, is required to ensure proper operation of this device. The thermal management medium is required to maintain baseplate < 105C for full rated power. 5. Non-standard output voltages are available. Please contact the factory for additional information. Copyright (c) Calex Mfg. Co. Inc All Rights Reserved 2401 Stanwell Drive, Concord Ca. 94520, Ph: 925-687-4411, Fax: 925-687-3333, www.calex.com Email: sales@calex.com Page 1 of 17 ECO 171121-1, 181204-1 500 WATT MXW SERIES DC/DC CONVERTER Electrical Specifications: Conditions: TA = 25C, airflow = 300 LFM (1.5m/s), VIN = 24VDC, unless otherwise specified. Specifications subject to change without notice. All Models Parameter Notes Min Typ Max Units 40 V 50 V Absolute Maximum Ratings Input Voltage Continuous 0 Transient (100ms) Operating Temperature Baseplate (100% load) Storage Temperature -40 105 C -55 125 C Isolation Characteristics and Safety Isolation Voltage Input to Output 2250 Input to Baseplate & Output to Baseplate 1500 Isolation Capacitance Isolation Resistance 10 Insulation Safety Rating V V 4500 pF 20 M Basic Designed to meet UL/cUL 60950, IEC/EN 60950-1 Feature Characteristics Fixed Switching Frequency Output Voltage Ripple has twice this frequency 200 Output Voltage Trim Range kHz 10 Remote Sense Compensation This function is not provided Output Overvoltage Protection Non-latching Over Temperature Shutdown (Baseplate) Non-latching Auto-Restart Period Applies to all protection features Turn-On Time from VIN % N/A 117 % 124 130 % 110 120 C 500 550 ms Time from UVLO to VO=90% VOUT (NOM) Resistive load 517 530 ms Turn-On time from ON/OFF Control Trim from ON to VO=90% VOUT (NOM) Resistive load 17 20 ms Rise Time VOUT from 10% to 90% 4 7.5 11 ms On State Pin open = ON or external voltage applied 2 12 V Current Control Leakage current 450 ON/OFF Control - Positive Logic OFF State Control Current Sinking 0.16 mA 0 0.8 V 0.3 0.36 mA 0.8 V 12 V ON/OFF Control - Negative Logic ON State Pin shorted to -INPUT or OFF State Pin open = OFF or 2 Thermal Characteristics Thermal resistance Baseplate to Ambient Copyright (c) Calex Mfg. Co. Inc All Rights Reserved 2401 Stanwell Drive, Concord Ca. 94520, Ph: 925-687-4411, Fax: 925-687-3333, www.calex.com Email: sales@calex.com Converter soldered to 3.95" x 2.5" x 0.07" layer / 2oz copper FR4 PCB 4 5.2 C/W Page 2 of 17 ECO 171121-1, 181204-1 500 WATT MXW SERIES DC/DC CONVERTER Electrical Specifications (Continued): Conditions: TA = 25C, airflow = 300 LFM (1.5m/s), VIN = 24VDC, unless otherwise specified. Specifications subject to change without notice. 24S12.41MXW Parameter Notes Min Typ Max Units 9 24 36 V Turn-on Threshold 8.2 8.5 8.8 V Turn-off Threshold 7.7 8 8.3 V 0.4 0.55 0.7 V 50.4 A Input Characteristics Operating Input Voltage Range Input Under Voltage Lockout Non-latching Lockout Hysteresis Voltage Maximum Input Current VIN = 9V, 80% Load VIN = 12V, 100% Load 46.2 A VIN = 24V, Output Shorted 65 mARMS Input Stand-by Current Converter Disabled 2 4 mA Input Current @ No Load Converter Enabled 240 280 mA Minimum Input Capacitance (external) ESR < 0.1 Inrush Transient Vin = 36V (0.4V/s) no input external capacitor 0.4 Input Terminal Ripple Current, iC 25 MHz bandwidth, 100% Load (Fig. 2) 620 470 F A2s 1 mARMS Output Characteristics Output Voltage Range Output Voltage Set Point Accuracy (50% Load) 11.64 12.00 12.36 V 11.88 12.00 12.12 V 0.05 0.15 % 0.08 0.15 % 0.015 0.03 %/C 15.6 V Output Regulation Over Line VIN = 9V to 36V Over Load VIN = 24V, Load 0% to 100% Temperature Coefficient Over Voltage Protection Output Ripple and Noise - 20 MHz bandwidth External Load Capacitance 14.0 (Fig. 3) 100% Load 120 180 mVPK-PK CEXT = 470 F/70m + 1 F ceramic 30 60 mVRMS Full Load (resistive) -40 C < Ta < +105 C CEXT 470 4700 F ESR 10 100 m 0 41 A 33.3 A 53.3 A 53.3 A 4 7 ARMS 450 mV Output Current Range (See Fig. A) VIN = 12V to 36V Current Limit Inception VIN = 12V - 36V 45.1 9V < VIN < 12V 40.6 VIN = 9 V RMS Short-Circuit Current 0 Non-latching, Continuous 49.2 Dynamic Response Load change 50% - 75%, di/dt = 1A/s Co = 470 F/70m + 1 F ceramic 320 Load change 50% - 100%, di/dt = 1A/s Co = 470 F/70m + 1 F ceramic 700 mV 600 s Setting Time to 1% of VOUT Efficiency: 100% Load Efficiency: 50% Load Copyright (c) Calex Mfg. Co. Inc All Rights Reserved 2401 Stanwell Drive, Concord Ca. 94520, Ph: 925-687-4411, Fax: 925-687-3333, www.calex.com Email: sales@calex.com VIN = 24 V 93.2 93.9 94.6 % VIN = 12 V 91.4 92.1 92.8 % VIN = 24 V 94.7 95.4 96.1 % VIN = 12 V 93.9 94.6 95.2 % Page 3 of 17 ECO 171121-1, 181204-1 500 WATT MXW SERIES DC/DC CONVERTER Electrical Specifications (Continued): Conditions: TA = 25C, airflow = 300 LFM (1.5m/s), VIN = 24VDC, unless otherwise specified. Specifications subject to change without notice. 24S24.21MXW Parameter Notes Min Typ Max Units 9 24 36 V Turn-on Threshold 8.2 8.5 8.8 V Turn-off Threshold 7.7 8 8.3 V 0.4 0.55 Input Characteristics Operating Input Voltage Range Input Under Voltage Lockout Non-latching Lockout Hysteresis Voltage Maximum Input Current 0.7 V VIN = 9V, 80% Load 50.4 A VIN = 12V, 100% Load 47.0 A VIN = 24V, Output Shorted 75 Input Stand-by Current Converter Disabled 2 4 mARMS mA Input Current @ No Load Converter Enabled 240 300 mA Minimum Input Capacitance (external) ESR < 0.1 Inrush Transient Vin = 36V (0.4V/s) no input external capacitor 0.4 1 A2s Input Terminal Ripple Current, iC 25 MHz bandwidth, 100% Load (Fig. 2) 680 470 F mARMS Output Characteristics Output Voltage Range Output Voltage Set Point Accuracy (50% Load) 23.28 24.00 24.72 V 23.76 24.00 24.24 V Output Regulation Over Line VIN = 9V to 36V 0.05 0.15 % Over Load VIN = 24V, Load 0% to 100% 0.08 0.15 % 0.015 0.03 %/C 31.2 V 360 mVPK-PK Temperature Coefficient Over Voltage Protection Output Ripple and Noise - 20 MHz bandwidth 28.1 (Fig. 3) 100% Load 240 CEXT = 470 F/70m + 1 F ceramic External Load Capacitance Output Current Range (See Fig. A) Current Limit Inception RMS Short-Circuit Current Full Load (resistive) -40 C < Ta < +105 C 80 mVRMS CEXT 470 50 2200 F ESR 10 100 m VIN = 12V to 36V 0 21 A VIN = 9 V 0 16.7 A 27.3 A 27.3 A 3.8 6 ARMS 420 mV VIN = 12V - 36V 23.1 9V < VIN < 12V 20.8 Non-latching, Continuous 25.2 Dynamic Response Load change 50% - 75%, di/dt = 1A/s Co = 470 F/70m + 1 F ceramic 280 Load change 50% - 100%, di/dt = 1A/s Co = 470 F/70m + 1 F ceramic 500 mV 600 s Setting Time to 1% of VOUT Efficiency: 100% Load Efficiency: 50% Load Copyright (c) Calex Mfg. Co. Inc All Rights Reserved 2401 Stanwell Drive, Concord Ca. 94520, Ph: 925-687-4411, Fax: 925-687-3333, www.calex.com Email: sales@calex.com VIN = 24 V 93.6 94.3 95 % VIN = 12 V 92.3 93.0 93.7 % VIN = 24 V 94.5 95.4 96.3 % VIN = 12 V 94.5 95.2 95.9 % Page 4 of 17 ECO 171121-1, 181204-1 500 WATT MXW SERIES DC/DC CONVERTER Electrical Specifications (Continued): Conditions: TA = 25C, airflow = 300 LFM (1.5m/s), VIN = 24VDC, unless otherwise specified. Specifications subject to change without notice. 24S28.18MXW Parameter Notes Min Typ Max Units 9 24 36 V Turn-on Threshold 8.2 8.5 8.8 V Turn-off Threshold 7.7 8 8.3 V 0.4 0.55 Input Characteristics Operating Input Voltage Range Input Under Voltage Lockout Non-latching Lockout Hysteresis Voltage Maximum Input Current 0.7 V VIN = 9V, 80% Load 50.4 A VIN = 12V, 100% Load 46.2 A VIN = 24V, Output Shorted 55 Input Stand-by Current Converter Disabled 2 4 mARMS mA Input Current @ No Load Converter Enabled 240 280 mA Minimum Input Capacitance (external) ESR < 0.1 Inrush Transient Vin = 36V (0.4V/s) no input external capacitor 0.4 1 A2s Input Terminal Ripple Current, iC 25 MHz bandwidth, 100% Load (Fig. 2) 550 470 F mARMS Output Characteristics Output Voltage Range Output Voltage Set Point Accuracy (50% Load) 27.16 28.00 28.84 V 27.72 28.00 28.28 V Output Regulation Over Line VIN = 9V to 36V 0.05 0.15 % Over Load VIN = 24V, Load 0% to 100% 0.08 0.15 % 0.015 0.03 %/C 36.4 V 380 mVPK-PK Temperature Coefficient Over Voltage Protection Output Ripple and Noise - 20 MHz bandwidth 32.8 (Fig. 3) 100% Load 280 CEXT = 470 F/70m + 1 F ceramic External Load Capacitance Output Current Range (See Fig. A) Current Limit Inception RMS Short-Circuit Current Full Load (resistive) -40 C < Ta < +105 C 85 mVRMS CEXT 470 50 2200 F ESR 10 100 m VIN = 12V to 36V 0 18 A VIN = 9 V 0 14.3 A VIN = 12V - 36V 19.8 23.4 A 9V < VIN < 12V 17.8 23.4 A 2.2 6 ARMS 410 Non-latching, Continuous Dynamic Response Load change 50% - 75%, di/dt = 1A/s Co = 470 F/70m + 1 F ceramic 270 Load change 50% - 100%, di/dt = 1A/s Co = 470 F/70m + 1 F ceramic 500 mV 800 s Setting Time to 1% of VOUT Efficiency: 100% Load Efficiency: 50% Load Copyright (c) Calex Mfg. Co. Inc All Rights Reserved 2401 Stanwell Drive, Concord Ca. 94520, Ph: 925-687-4411, Fax: 925-687-3333, www.calex.com Email: sales@calex.com mV VIN = 24 V 94.3 95.0 95.7 % VIN = 12 V 93.1 93.8 94.5 % VIN = 24 V 95.0 95.7 96.4 % VIN = 12 V 94.1 94.8 95.5 % Page 5 of 17 ECO 171121-1, 181204-1 500 WATT MXW SERIES DC/DC CONVERTER Environmental and Mechanical Specifications: Specifications subject to change without notice. Parameter Notes Min Typ Max Units Environmental Operating Humidity Non-condensing 95 % Storage Humidity Non-condensing 95 % ROHS Compliance 1 See Calex Website http://www.calex.com/RoHS.html for the complete RoHS Compliance Statement Shock and Vibration Designed to meet MIL-STD-810G for functional shock and vibration Water Washability Not recommended for water wash process. Contact the factory for more information. Mechanical Weight 3.85 Ounces 109.2 Grams PCB Operating Temperature 130 Tg C 170 Pins 1 ,4, 5 and 9 Through Hole Pin Diameters Pins 3 and 7 Through Hole Pin Material Through Hole Pin Finish C 0.079 0.081 0.083 2.006 2.057 2.108 mm 0.038 0.04 0.042 Inches 0.965 1.016 1.067 mm Pins 1,4,5 and 9 C14500 or C1100 Copper Alloy Pins 3 and 7 Brass Alloy TB3 or "Eco Brass" All pins 10" Gold over Nickel Case Dimensions Case Material Inches 2.4 x 2.5 x 0.52 Inches 60.96 x 63.50 x 13.21 mm Plastic: Vectra LCP FIT30: 1/2 - 16 EDM Finish Material Baseplate Aluminum Flatness 0.008 Inches 0.20 mm 5.4 MHrs Reliability MTBF Telcordia SR-332, Method 1 Case 1 50% electrical stress, 40C components Agency Approvals UL60950 Approved EMI and Regulatory Compliance Conducted Emissions MIL-STD-461F CE102 with external EMI filter network (see Figs, 28 and 29) Additional Notes: 1. the RoHS marking is as follows: Output Power vs. Input Voltage Output Power [W] 600 500 400 300 200 100 0 9 12 15 18 21 24 27 30 33 36 Input Voltage [V] Fig. A : Output Power vs. Input Voltage Copyright (c) Calex Mfg. Co. Inc All Rights Reserved 2401 Stanwell Drive, Concord Ca. 94520, Ph: 925-687-4411, Fax: 925-687-3333, www.calex.com Email: sales@calex.com Page 6 of 17 ECO 171121-1, 181204-1 500 WATT MXW SERIES DC/DC CONVERTER Operations: Input and Output Capacitance In many applications, the inductance associated with the distribution from the power source to the input of the converter can affect the stability of the converter. This becomes of great consideration for input voltage at 12V or below. In order to enable proper operation of the converter, in particular during load transients, an additional input capacitor is required. Minimum required input capacitance, mounted close to the input pins, is 1000F with ESR < 0.1 . Since inductance of the input power cables could have significant voltage drop due to rate of change of input current di(in)/dt during transient load operation an external capacitance on the output of the converter is required to reduce di(in)/dt. It is required to use at least 470 F (ESR < 0.07) on the output. Another constraint is minimum rms current rating of the input and output capacitors which is application dependent. One component of input rms current handled by input capacitor is high frequency component at switching frequency of the converter (typ. 400kHz) and is specified under "Input terminal ripple current" ic. Typical values at full rated load and 24 Vin are provided in Section "Characteristic Waveforms" for each model and are in range of 0.55A - 0.7A. Second component of the ripple current is due to reflected step load current on the input of the converter. Similar consideration needs to be taken into account for output capacitor and in particular step load ripple current component. Consult the factory for further application guidelines. Additionally, for EMI conducted measurement it is necessary to use 5H LISNs instead of typical 50H LISNs. ON/OFF (Pin 3) The ON/OFF pin is used to turn the power converter on or off remotely via a system signal and has positive logic. A typical connection for remote ON/OFF function is shown in Fig. 1. The positive logic version turns on when the ON/OFF pin is at logic high and turns off when at logic low. The converter is on when the ON/OFF pin is either left open or external voltage not more than 12V is applied between ON/OFF pin and -INPUT pin. See the Electrical Specifications for logic high/low definitions. The negative logic version turns on when the ON/OFF pin is at logic low and turns off when at logic high. The converter is on when the ON/OFF pin is either shorted to -INPUT pin or kept below 0.8V. The converter is off when the ON/OFF pin is either left open or external voltage greater than 2V and not more than 12V is applied between ON/OFF pin and -INPUT pin. See the Electrical Specifications for logic high/low definitions. The ON/OFF pin is internally pulled up to typically 4.5V via resistor and connected to internal logic circuit via RC circuit in order to filter out noise that may occur on the ON/OFF pin. A properly de-bounced mechanical switch, open-collector transistor, or FET can be used to drive the input of the ON/OFF pin. The device must be capable of sinking up to 0.36mA at a low level voltage of < 0.8V. During logic high, the typical maximum voltage at ON/OFF pin (generated by the converter) is 4.5V, and the maximum allowable leakage current is 160A. If not using the remote on/off feature leave the ON/OFF pin open. TTL Logic Level - The range between 0.81V as maximum turn off voltage and 2V as minimum turn on voltage is considered the dead-band. Operation in the dead-band is not recommended. External voltage for ON/OFF control should not be applied when there is no input power voltage applied to the converter. Protection Features: Input Undervoltage lockout (UVLO) Input undervoltage lockout is standard with this converter. The converter will shut down when the input voltage drops below a pre-determined voltage. The input voltage must be typically above 8.5V for the converter to turn on. Once the converter has been turned on, it will shut off when the input voltage drops typically below 8V. If the converter is started by input voltage (ON/OFF (pin 3) left open) there is typically 500msec delay from the moment when input voltage is above 8.5V turn-on voltage and the time when output voltage starts rising. This delay is intentionally provided to prevent potential startup issues especially at low input voltages. Page 7 of 17 Copyright (c) Calex Mfg. Co. Inc All Rights Reserved 2401 Stanwell Drive, Concord Ca. 94520, Ph: 925-687-4411, Fax: 925-687-3333, www.calex.com Email: sales@calex.com ECO 171121-1, 181204-1 500 WATT MXW SERIES DC/DC CONVERTER Output Overcurrent Protection (OCP) Electromagnetic Compatibility (EMC) The converter is protected against overcurrent or short circuit conditions. Upon sensing an overcurrent condition, the converter will switch to constant current operation and thereby begin to reduce output voltage. When the output voltage drops below approx. 75% of the nominal value of output voltage, the converter will shut down. Once the converter has shut down, it will attempt to restart nominally every 500msec with a typical 3% duty cycle. The attempted restart will continue indefinitely until the overload or short circuit conditions are removed or the output voltage rises above 75% of its nominal value. Once the output current is brought back into its specified range, the converter automatically exits the hiccup mode and continues normal operation. During initial startup, if output voltage does not exceed typical 75% of nominal output voltage within 20 msec after the converter is enabled, the converter will be shut down and will attempt to restart after 500 msec. EMC requirements must be met at the end-product system level, as no specific standards dedicated to EMC characteristics of board mounted component dcdc converters exist. Output Overvoltage Protection (OVP) The converter will shut down if the output voltage across VOUT (+) (Pin 5) and VOUT (-) (Pin 9) exceeds the threshold of the OVP circuitry. The OVP circuitry contains its own reference, independent of the output voltage regulation loop. Once the converter has shut down, it will attempt to restart every 500 msec until the OVP condition is removed. Over Temperature Protection (OTP) The MXW converters have non-latching over temperature protection. It will shut down and disable the output if temperature at the center of the base place exceeds a threshold of 112C (typical). The converter will automatically restart when the base temperature has decreased by approximately 20C. Safety Requirements Basic Insulation is provided between input and the output. The converters have no internal fuse. To comply with safety agencies requirements, a fast-acting or timedelay fuse is to be provided in the unearthed lead. Recommended fuse values are: a) 60A for 9V < VIN < 18V a) 30A for 18V < VIN < 36V With the addition of a single stage external filter, the MXW converters will pass the requirements of MILSTD-461F CE102 Base Curve for conducted emissions. Absence of the Remote Sense Pins Customers should be aware that MXW converters do not have a Remote Sense feature. Care should be taken to minimize voltage drop on the user's motherboard as well as if trim function is used. Output Voltage Adjust/TRIM (Pin 7) The TRIM pin allows user to adjust output voltage 10% up or down relative to rated nominal voltage by addition of external trim resistor. Due to absence of Remote Sense Pins, an external trim resistor should be connected to output pins using Kelvin connection. If trimming is not used, the TRIM pin should be left open. Trim Down - Decrease Output Voltage Trimming down is accomplished by connecting an external resistor, Rtrim-down, between the TRIM (pin 7) and the VOUT(-) (pin 9) using Kelvin connection, with a value of: Rtrim-down = - 60.2 [k] Where, Rtrim-down= Required value of the trim-down resistor [k] VO (nom) = Nominal value of output voltage [V] VO (req) = Required value of output voltage [V] = ( ) ( ( ) ) [%] To trim the output voltage 10% (=10) down, required external trim resistance is. Rtrim-down = 10 - 60.2 = 240.8 k Page 8 of 17 Copyright (c) Calex Mfg. Co. Inc All Rights Reserved 2401 Stanwell Drive, Concord Ca. 94520, Ph: 925-687-4411, Fax: 925-687-3333, www.calex.com Email: sales@calex.com ECO 171121-1, 181204-1 500 WATT MXW SERIES DC/DC CONVERTER Trim Up - Increase Output Voltage Thermal Derating Trimming up is accomplished by connecting an external resistor, Rtrim-up, between the TRIM (pin 7) and the VOUT(+) (pin5) using Kelvin connection, with a value of: There are two most common applications: 1) the MXW converter is thermally attached to a cold plate inside chassis without any forced internal air circulation; 2) the MXW converter is mounted in an open chassis on system board with forced airflow with or without an additional heatsink attached to the baseplate of the MXW converter. Rtrim-up = 30.1 VO NOM (100+) 1.225 - (100+2) [k] To trim the output voltage up, for example 24V to 26.4V, =10 and required external resistor is: Rtrim-up = 30.1 ) ( . - ( ) = 6125 k Note that trimming output voltage more than 10% is not recommended and OVP may be tripped. Active Voltage Programming In applications where output voltage needs to be adjusted actively, an external voltage source, such as for example a Digital-to-Analog converter (DAC), capable of both sourcing and sinking current can be used. It should be connected with series resister Rg across TRIM (pin 7) and VOUT(-) (pin 9) using Kelvin connection. Please contact Calex technical representative for more details. Thermal Consideration The MXW converter can operate in a variety of thermal environments. However, in order to ensure reliable operation of the converter, sufficient cooling should be provided. The MXW converter is encapsulated in plastic case with metal baseplate on the top. In order to improve thermal performance, power components inside the unit are thermally coupled to the baseplate. In addition, thermal design of the converter is enhanced by use of input and out pins as heat transfer elements. Heat is removed from the converter by conduction, convection and radiation. There are several factors such as ambient temperature, airflow, converter power dissipation, converter orientation how converter is mounted as well as the need for increased reliability that need to be taken into account in order to achieve required performance. It is highly recommended to measure temperature in the middle of the baseplate in particular application to ensure that proper cooling of the convert is provided. A reduction in the operating temperature of the converter will result in an increased reliability. The best thermal results are achieved in application 1) since the converter is cooled entirely by conduction of heat from the top surface of the converter to a cold plate and temperature of the components is determined by the temperature of the cold plate. There is also some additional heat removal through the converters pins to the metal layers in the system board. It is highly recommended to solder pins to the system board rather than using receptacles. Typical derating output power and current are shown in Figs. 10-15 for various baseplate temperatures up to 105C. The converter was solder to the test card: 4.26" x 5.9" 4 layers FR4 PCB with 3Oz Cu inner layers and 2 Oz Cu outer layers, covered with solder mask. Note that operating converter at these limits for prolonged time will affect reliability. Soldering Guidelines The ROHS-compliant through hole MXW converters use Sn/Ag/Cu Pb-free solder and ROHS compliant components. They are designed to be processed through wave soldering machines. The pins are 100% matte tin over nickel plated and compatible with both Pb and Pb-free wave soldering processes. It is recommended to follow specifications below when installing and soldering MXW converters. Exceeding these specifications may cause damage to the MXW converter. Wave Solder Guideline for Sn/Ag/Cu based solders Maximum Preheat Temperature 115C Maximum Pot Temperature 270C Maximum Solder Dwell Time 7 seconds Wave Solder Guideline for SN/Pb based solders Maximum Preheat Temperature 105C Maximum Pot Temperature 250C Maximum Solder Dwell Time 6 seconds MXW converters are not recommended for water wash process. Contact the factory for additional information if water wash is necessary. Page 9 of 17 Copyright (c) Calex Mfg. Co. Inc All Rights Reserved 2401 Stanwell Drive, Concord Ca. 94520, Ph: 925-687-4411, Fax: 925-687-3333, www.calex.com Email: sales@calex.com ECO 171121-1, 181204-1 500 WATT MXW SERIES DC/DC CONVERTER Test Configurations: Fig. 2: Test setup for measuring input reflected ripple currents iC and iS. Fig. 3: Test setup for measuring output voltage ripple, startup and step load transient waveforms. Page 10 of 17 Copyright (c) Calex Mfg. Co. Inc All Rights Reserved 2401 Stanwell Drive, Concord Ca. 94520, Ph: 925-687-4411, Fax: 925-687-3333, www.calex.com Email: sales@calex.com ECO 171121-1, 181204-1 500 WATT MXW SERIES DC/DC CONVERTER Characteristic Curves - Efficiency and Power Dissipation Fig. 4: 24S12.41MXW (ROHS) Efficiency Curve Fig. 5: 24S12.41MXW (ROHS) Power Dissipation Fig. 6: 24S24.21MXW (ROHS) Efficiency Curve Fig. 7: 24S24.21MXW (ROHS) Power Dissipation Fig. 8: 24S28.18MXW (ROHS) Efficiency Curve Fig. 9: 24S28.18MXW (ROHS) Power Dissipation Page 11 of 17 Copyright (c) Calex Mfg. Co. Inc All Rights Reserved 2401 Stanwell Drive, Concord Ca. 94520, Ph: 925-687-4411, Fax: 925-687-3333, www.calex.com Email: sales@calex.com ECO 171121-1, 181204-1 500 WATT MXW SERIES DC/DC CONVERTER Characteristic Curves - Derating Curves Output Power vs. Base Plate Temperature - 24S12.41MXW Output Current vs. Base Plate Temperature - 24S12.41MXW 550 45 500 40 450 35 Output Current [W] Output Power [W] 400 350 300 250 200 150 30 25 20 15 10 100 5 50 0 0 25 30 35 40 45 50 55 60 65 70 75 80 Baseplate Temperature [C] Vin=9V Vin=12V 85 90 95 100 105 25 30 35 40 45 50 55 60 65 70 75 80 Baseplate Temperature [C] Vin=9V Vin=24V-36V Vin=12V 85 90 95 100 105 Vin=24V - 36V Fig. 11: 24S12.41MXW (ROHS) Derating Curve Fig. 10: 24S12.41MXW (ROHS) Derating Curve Output Current vs. Base Plate Temperature - 24S24.21MXW Output Power vs. Base Plate Temperature - 24S24.21MXW 550 24 500 21 450 18 Output Current [W] Output Power [W] 400 350 300 250 200 150 15 12 9 6 100 3 50 0 0 25 30 35 40 45 50 55 60 65 70 75 80 Baseplate Temperature [C] Vin=9V Vin=12V 85 90 95 100 105 25 30 35 40 45 50 55 60 65 70 75 80 Baseplate Temperature [C] Vin=9V Vin=24V-36V Vin=12V 85 90 95 100 105 Vin=24V - 36V Fig. 13: 24S24.21MXW (ROHS) Derating Curve Fig. 12: 24S24.21MXW (ROHS) Derating Curve Output Current vs. Base Plate Temperature - 24S28.18MXW Output Power vs. Base Plate Temperature - 24S28.18MXW 550 21 500 18 450 Output Current [W] Output Power [W] 400 350 300 250 200 150 100 15 12 9 6 3 50 0 0 25 30 35 40 45 50 55 60 65 70 75 80 Baseplate Temperature [C] Vin=9V Vin=12V 85 90 95 100 105 Vin=24V-36V Fig. 14: 24S28.18MXW (ROHS) Derating Curve 25 30 35 40 45 50 55 60 65 70 75 80 Baseplate Temperature [C] Vin=9V Vin=12V 85 90 95 100 105 Vin=24V - 36V Fig. 15: 24S28.18MXW (ROHS) Derating Curve Page 12 of 17 Copyright (c) Calex Mfg. Co. Inc All Rights Reserved 2401 Stanwell Drive, Concord Ca. 94520, Ph: 925-687-4411, Fax: 925-687-3333, www.calex.com Email: sales@calex.com ECO 171121-1, 181204-1 500 WATT MXW SERIES DC/DC CONVERTER Characteristic Waveforms - 24S12.41MXW (ROHS) Fig. 16: Turn-on by ON/OFF transient (with VIN applied) at full rated load current (resistive) at VIN = 24V. Top trace (C1): ON/OFF signal (5V/div.). Bottom trace (C4): Output voltage (5 V/div.). Time 5 ms/div. Fig. 17: Turn-on by VIN (ON/OFF high) transient at full rated load current (resistive) at VIN = 24V. Top trace (C2): Input voltage VIN (10 V/div.). Bottom trace (C4): Output voltage (5 V/div.). Time 100 ms/div. Fig. 18: Output voltage response to load current step change 50% 75% - 50% (20.5A - 31.5A - 20.5A) with di/dt = 1A/s at VIN = 24V. Top trace (C4): Output voltage (200 mV/div.). Bottom trace (C3): Load current (20A/div.). CO 470F/70m. Time: 1ms/div. Fig. 19: Output voltage response to load current step change 50% 100% - 50% (20.5A - 41A - 20.5A) with di/dt = 1A/s at VIN = 24V. Top trace (C4): Output voltage (500 mV/div.). Bottom trace (C3): Load current (20A/div.). CO 470F/70m. Time: 1ms/div. Fig. 20: Output voltage ripple (100mv/div.) at full rated load current into a resistive load at VIN = 24V. CO 470F/70m. Time: 2s/div. Fig. 21: Input reflected ripple current, iC (500 mA/mV), measured at input terminals at full rated load current at VIN = 24V. Refer to Fig. 2 for test setup. Time: 2 s/div. RMS input ripple current is 1.235*500mA = 617.5mA. Page 13 of 17 Copyright (c) Calex Mfg. Co. Inc All Rights Reserved 2401 Stanwell Drive, Concord Ca. 94520, Ph: 925-687-4411, Fax: 925-687-3333, www.calex.com Email: sales@calex.com ECO 171121-1, 181204-1 500 WATT MXW SERIES DC/DC CONVERTER Characteristic Waveforms - 24S24.21MXW (ROHS) Fig. 22: Turn-on by ON/OFF transient (with VIN applied) at full rated load current (resistive) at VIN = 24V. Top trace (C1): ON/OFF signal (5V/div.). Bottom trace (C4): Output voltage (10 V/div.). Time 5 ms/div. Fig. 23: Turn-on by VIN transient (ON/OFF high) at full rated load current (resistive) at VIN = 24V. Top trace (C2): Input voltage VIN (10 V/div.). Bottom trace (C4): Output voltage (10 V/div.). Time 100 ms/div. Fig. 24: Output voltage response to load current step change 50% 75% - 50% (10.5A - 15.75A - 10.5A) with di/dt = 1A/s at VIN = 24V. Top trace (C4): Output voltage (200 mV/div.). Bottom trace (C3): Load current (10A/div.). CO 470F/70m. Time: 1ms/div. Fig. 25: Output voltage response to load current step change 50% 100% - 50% (10.5A - 21A - 10.5A) with di/dt = 1A/s at VIN = 24V. Top trace (C4): Output voltage (500 mV/div.). Bottom trace (C3): Load current (10A/div.). CO 470F/70m. Time: 1ms/div. Fig. 26: Output voltage ripple (200mv/div.) at full rated load current into a resistive load at VIN = 24V. CO 470F/70m. Time: 2s/div. Fig. 27: Input reflected ripple current, iC (500 mA/mV), measured at input terminals at full rated load current at VIN = 24V. Refer to Fig. 2 for test setup. Time: 2 s/div. RMS input ripple current is 1.359*500mA = 679.5mA. Page 14 of 17 Copyright (c) Calex Mfg. Co. Inc All Rights Reserved 2401 Stanwell Drive, Concord Ca. 94520, Ph: 925-687-4411, Fax: 925-687-3333, www.calex.com Email: sales@calex.com ECO 171121-1, 181204-1 500 WATT MXW SERIES DC/DC CONVERTER Characteristic Waveforms - 24S28.18MXW (ROHS) Fig. 28: Turn-on by ON/OFF transient (with VIN applied) at full rated load current (resistive) at VIN = 24V. Top trace (C1): ON/OFF signal (5V/div.). Bottom trace (C4): Output voltage (10 V/div.). Time 5 ms/div. Fig. 29: Turn-on by VIN transient (ON/OFF high) at full rated load current (resistive) at VIN = 24V. Top trace (C2): Input voltage VIN (10 V/div.). Bottom trace (C4): Output voltage (10 V/div.). Time 100 ms/div. Fig. 30: Output voltage response to load current step change 50% 75% - 50% (9A - 13.5A - 9A) with di/dt = 1A/s at VIN = 24V. Top trace (C4): Output voltage (200 mV/div.). Bottom trace (C3): Load current (10A/div.). CO 470F/70m. Time: 1ms/div. Fig. 31: Output voltage response to load current step change 50% 100% - 50% (9A - 18A - 9A) with di/dt = 1A/s at VIN = 24V. Top trace (C4): Output voltage (500 mV/div.). Bottom trace (C3): Load current (10A/div.). CO 470F/70m. Time: 1ms/div. Fig. 32: Output voltage ripple (200mv/div.) at full rated load current into a resistive load at VIN = 24V. CO 470F/70m. Time: 2s/div. Fig. 33: Input reflected ripple current, iC (500 mA/mV), measured at input terminals at full rated load current at VIN = 24V. Refer to Fig. 2 for test setup. Time: 2 s/div. RMS input ripple current is 1.098*500mA = 549mA. Page 15 of 17 Copyright (c) Calex Mfg. Co. Inc All Rights Reserved 2401 Stanwell Drive, Concord Ca. 94520, Ph: 925-687-4411, Fax: 925-687-3333, www.calex.com Email: sales@calex.com ECO 171121-1, 181204-1 500 WATT MXW SERIES DC/DC CONVERTER EMC Consideration: The filter schematic for suggested input filter configuration as tested to meet the conducted emission limits of MILSTD-461F CE102 Base Curve is shown in Fig. 34. The plots of conducted EMI spectrum are shown in figure 35. Note: Customer is ultimately responsible for the proper selection, component rating and verification of the suggested parts based on the end application. Comp. Des. C1, C2, C12, C14 C3, C4, C5, C6 C7, C8, C9, C10, C11, C13 L1 Description 470F/50V/70m Electrolytic Capacitor (Vishay MAL214699108E3 or equivalent) 4.7nF/1210/X7R/1500V Ceramic Capacitor 10F/1210/X7R/50V Ceramic Capacitor CM choke: L = 130H, Llkg = 0.6H (4 turns on toroid 22.1mm x 13.7mm x 7.92mm) Fig. 34: Typical input EMI filter circuit to attenuate conducted emissions per MIL-STD-461F CE102 Base Curve. a) Without input filter. CIN = 2 x 470F/50V/70m. b) With input filter from Fig. 34. Fig. 35: Input conducted emissions measurement (Typ.) of 24S24.21MXW (ROHS) Page 16 of 17 Copyright (c) Calex Mfg. Co. Inc All Rights Reserved 2401 Stanwell Drive, Concord Ca. 94520, Ph: 925-687-4411, Fax: 925-687-3333, www.calex.com Email: sales@calex.com ECO 171121-1, 181204-1 500 WATT MXW SERIES DC/DC CONVERTER Mechanical Specification: Notes: Unless otherwise specified: All dimensions are in inches [millimeters] Tolerances: x.xx in. 0.02 in [x.x mm 0.5mm] x.xxx in. 0.010 in [x.xx mm 0.25mm] Torque fasteners into threaded mounting inserts at 10in.lbs. or less. Greater torque may result in damage to unit and void the warranty. Input Output Connections: Pin 1 3 Name -INPUT ON/OFF 4 5 7 9 +INPUT +OUTPUT TRIM -OUTPUT Function Negative input voltage TTL input with internal pull up, referenced to -INPUT, used to turn converter on and off Positive input voltage Positive output voltage Output voltage trim Negative output voltage Notes: 1) Pinout is inconsistent between manufacturers of the half brick converters. Make sure to follow the pin function, the pin number, when laying out your board. 2) Pin diameter for the input pins of the MXW converters has diameter 0.081" due to high current at low line, and is different from other manufacturers of the half brick. Make sure to follow pin dimensions in your application. Page 17 of 17 Copyright (c) Calex Mfg. Co. Inc All Rights Reserved 2401 Stanwell Drive, Concord Ca. 94520, Ph: 925-687-4411, Fax: 925-687-3333, www.calex.com Email: sales@calex.com ECO 171121-1, 181204-1